Transcript weaverjm.faculty.udmercy.edu

Design For Health & Safety
MPD575 DFX
Jonathan Weaver
Development History
• Material Prepared by Cohort 1 (2001)
– Beth Robinson
– Robin Schulz
• Revised by Cohort 1 (2001)
– Dave Chronowski
– Mark Halseth
– Andrew Kernahan
– Roger Maynard
• Edited by Bill Dowling, Jim Stevens, Keith
Warner, Mac Lunn, Drew Kammerzell, Joe
Lambrecht
MPD575 DF Health & Safety
Design for Health & Safety
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Introduction
Manufacturing Hazards
Consumer Products
Automotive Products
Driver Distraction
Key Principles
Case Studies
References
MPD575 DF Health & Safety
Introduction
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Define safety and hazards
Define “designing for health and safety”
Benefits
Historical background
Standards and codes
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Safety
• Safety: a condition which is free from exposure to
danger, injury, or loss
• Safety is said to be a quality of averting or not
causing injuries, danger, or loss
• ‘Safe’ implies freedom from danger
• A ‘safe’ product is not free from all dangers under all
conditions
• A product can be said to be the safest, even though it
is not absolutely safe
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Hazard
• Hazard: the existence of a danger which one can
foresee but not avoid
• Examples: hazardous waste or hazardous
occupations - dangers that are known to be present
• In this discussion hazard is considered any sort of
threat to personal safety
• Hazards include both foreseeable and avoidable
threats
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Designing for Health & Safety
• The integration of hazard analysis and risk
assessment methods early in the design and
engineering stages and the taking of the
actions necessary so that the risks of injury or
damage are at an acceptable level
• Encompasses facilities, hardware, equipment,
tooling, materials, layout and configuration,
energy controls and environmental concerns
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Why Safety Through Design?
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• Main business goal: improve earnings per
share or return on investment
• The following benefits can be achieved if
decisions affecting safety, health and the
environment are integrated into the early
stages of the design process:
– Reduce injuries, illnesses, damage to the
environment
– Improve productivity, operating costs
– Avoid changes to correct the design
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Costs of Injuries and Death
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Cost of Motor Vehicle Crashes
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Historical Background
• Initial design efforts were focused on solving a
problem and getting the product to work as intended
• Little attention was paid to the safety aspects of the
design
• Mechanical workplace hazards have existed for
almost 300 years
• Workplace injury costs increased, causing legislation
to be introduced
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Historical Background
• Workers received compensation insurance for
workplace injuries
• Insurance carriers began the development of
safety improvements in an effort to control
costs
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Standards and Codes
• Standards
– Government
– Industry
– Commercial
• Codes
– Building
– Fire
– Electrical
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Government Standards
• OSHA: Occupational Safety and Health
Administration
• CPSC: Consumer Product Safety Commission
• NHTSA: National Highway Traffic Safety
Administration
• ATF: Bureau of Alcohol, Tobacco, and Firearms
• FDA: Food and Drug Administration
• EPA: Environmental Protection Agency
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Government Standards
• Regulations are initially published in the Federal
Register (common format)
• This publication is issued every day the federal
government is open
• Once approved, they are included in the Code of
Federal Regulations (CFR)
• There are 50 CFR titles covering all aspects of the
federal government
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Industry Standards
• Noted for their individuality
• In the 1990’s there were about 350 standardsgenerating organizations in the U.S.
• Each organization writes standards for their area of
interest and uses its own approach
• Index and Directory of U.S. Industry Standards, a 2
volume set including more than 35,000 documents
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Industry Standards
• Litigation
– The American Society of Mechanical Engineers
issued the ‘Boiler and Pressure Vessel Code’
– The ASME was successfully sued by the maker of
a device used to indicate the liquid level in boilers
– The ASME code unfairly discriminated against this
‘hydrolevel’ device
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Industry Standards
• National Safety Council, founded in 1913, publishes
books and pamphlets regarding safety considerations
for a wide variety of products
• The NSC keeps statistics on accidents, including
cause, frequency and severity measures
• Provides input to the organizations that write the
standards
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Industry Standards Other organizations
• National Fire Protection Association (NFPA)
– National electric and fire codes
• Underwriters Laboratories
– independent, not for profit org. founded in 1894
– Was sponsored by insurance underwriters to
“establish, maintain, and operate laboratories for
the examination and testing of devices, systems
and materials to determine their relation to hazards
to life and property”
• UK has Thatcham that is similar to UL; Canada
CSA, EU CE, etc.
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Product Standards
• American Lumber Standards are issued by several
regional wood products associations and contain
their rules for the grading of particular varieties of
wood
• Voluntary product standards are developed under
procedure published by the Department of
Commerce in Part 10 of Title 15 of the Code of
Federal Regulations
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Product Standards
• The Voluntary Products Standards program is
administered by the National Institute of Standards
and Technology (NIST)
• The purpose of these is to establish nationally
recognized requirements for various products
• Strictly voluntary, do not have the force of law except
when cited as a reference in legal codes, documents,
or contracts
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Building Codes
• Initiated in 1905 by the insurance industry
• The purpose was to improve safety and fire
protection features of a building
• The intent was to reduce loss of life and fire damage
to property through prudent design considerations
• These codes have the force of law
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Building Codes
• Regional codes
– Western U.S. uses the ‘Uniform Building Code’
originally issued by the International Conference of
Building Officials in 1927 (3 year revision program)
– Southeastern U.S. uses the Standard Building
Code’ published by the Southern Building Code
Congress International originally in 1945 (annual
revisions)
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Fire Codes
• In 1896, the NFPA issued standard 13 to make
certain automatic sprinkler systems were properly
designed, installed and maintained
• Annually issue the ‘National Fire Codes’ including the
sprinkler and electrical codes
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Design for Health and Safety
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Introduction
Manufacturing Hazards
Consumer Products
Automotive Products
Driver Distraction
Key Principles
Case Studies
References
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Manufacturing Hazards
• Types
– Kinetic
– Potential
– Chemical
– Environmental
• Mitigation Hierarchy
– Design
– Guards and Guarding
– Interlocks
– Warnings
– Operator Training
– Personal Protective Equipment
6/13/2012
Keith Warner
Types of Hazards
• Kinetic:
Energy in motion such as rotational, translational,
oscillatory, compression, expansion, etc.
• Potential:
Energy in storage such as pressure, electrical,
chemical, thermal, gravitational, etc.
• Environmental:
Sound decibels, Light levels, Air quality, Cleanliness,
Temperature, etc.
• Chemical:
Solvents, acids, gasses, etc.
6/13/2012
Keith Warner
Types of Hazards
• Kinematics: Operators can get a part of their body or
clothing, gloves, or tools too close to mechanical
machinery causing great injury.
– Conveyors have large amounts of kinetic energy
which could cause damage to any object
interfering with their motion
• Energy: Components that store energy such as
springs and counterbalancing weights, pneumatic
and hydraulic equipment.
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Types of Hazards
• Electrical
– Shock received from short circuits
– Electrical faults can cause fires, resulting in severe
burns or death
• Environmental
– Operators can suffer hearing loss from loud
equipment
• ‘Nip’ (or pinch) points found at various locations on
machinery
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Nip Points
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Mitigation Hazards
• Design the hazard out of the product
• Provide guards for hazards that cannot be designed out
• Provide Interlocks (electrical/mechanical) to ensure
guards are in place or operators cannot inadvertently
actuate machinery while in a compromised position
• Provide warnings or instructions to alert the user or
operator of the product that a hazard exists
• Train the operator in the proper/safe use of the
equipment
• Provide the necessary protective equipment: gloves,
glasses, ear plugs, etc.
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Mitigating Hazards Through Design
• Ideally done early in the design stage
• Test samples prior to production to reveal latent hazards
not earlier recognizable
• One of the most common charges brought by plaintiffs’
attorneys is that the product was not adequately tested
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Mitigating Hazards: Guard & Guarding
• When a hazard cannot be designed out of a product
• Three main types of guards for machinery:
– fixed guards
– interlocked guards
– adjustable guards
• These protective features are attached to the machine
and can be removed when the machine is being serviced
or changed over
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Mitigating Hazards Example
The hazard presented by the closing of the dies in a
stamping operation:
• The two halves of the die must come together with
sufficient force to permanently change the shape of the
material
• If any part of the operator’s body gets caught in the die,
substantial injury could result
• Guards (light-bars) are used to prevent this occurrence
(by stopping the press if sensor is tripped)
• Controls can be used that require simultaneous activation
by both an operator’s hands to engage the press
(interlocks)
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Mitigating Hazards: Locations
• Three common locations:
– The point of operation
– The power transmission system
– All other moving parts
• Guards should be provided for all three
classes of locations and specific regulations
published by OSHA relate to each one of them
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Mitigating Hazards: Warnings
• Perhaps the weakest solution is to warn operators of
the existence of the hazard
• A great deal of attention is given to the subject of
warnings because of increasing product liability
litigation, charging that inadequate warnings to the
user of a product caused personal injury or property
damage
• Proper instruction and training in the safe use of the
equipment will strengthen the recognition of warning
signals
MPD575 DF Health & Safety
Design for Health and Safety
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Introduction
Manufacturing Hazards
Consumer Products
Automotive Products
Driver Distraction
Key Principles
Case Studies
References
MPD575 DF Health & Safety
Consumer Products
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Defined
Banned Products
CPSC Standards
Injury and Death Statistics
Examples of Faulty Consumer Product
Designs
• Recalls
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Consumer Products
To regulate consumer products, the government set up the
Consumer Product Safety Commission (CPSC) as an
independent agency to accomplish four objectives:
– To protect the public against unreasonable risks of injury
associated with consumer products
– To assist consumers in evaluating the comparative safety
of consumer products
– To develop uniform safety standards for consumer products
and to minimize conflicting state and local regulations
– To promote research and investigation into the causes and
prevention of product-related deaths, illnesses, and injuries
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What are Consumer Products?
• Usually purchased in small quantities
• Distributed through a long channel with many steps
between the manufacturer and consumer
• Heavy amount of advertising
• Usually used around the home, in a residential or
social setting
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Consumer Products
The Consumer Product Safety Act defines consumer
products as:
– Any article, or component thereof, produced or
distributed for sale to a consumer for personal use,
consumption, or enjoyment in or around a
permanent or temporary household or residence,
a school, in recreation or otherwise
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What Consumer Products Are
• 15,000 types of consumer products
• From coffee makers, to toys, to lawn mowers,
to fireworks
• Child resistant packaging of food and drugs
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What Consumer Products Are Not
• Does not include industrial or commercial products
• Does not include food, drugs, cosmetics, boats,
aircraft, tobacco products, motor vehicles and their
equipment, pesticides, and firearms
• Not included because they are regulated by other
federal laws (Department of Transportation, Food
and Drug Administration, Environmental Protection
Agency, Occupational Safety and Health
Administration, and Bureau of Alcohol, Tobacco and
Firearms)
MPD575 DF Health & Safety
Food and Drug Administration
• Food
– Foodborne Illness, Nutrition...
• Drugs
– Prescription, Over-the-Counter, Generic...
• Medical Devices
– Pacemakers, Contact Lenses, Hearing Aids...
• Biologics
– Vaccines, Blood Products...
• Animal Feed and Drugs
– Livestock, Pets...
• Cosmetics
– Safety, Labeling...
• Radiation-Emitting Products
– Cell Phones, Lasers, Microwaves
MPD575 DF Health & Safety
Banned Products
• Unstable refuse bins
– In June 1978 metal bins of 1 cubic yard capacity or
larger which could tip over and crush young children
were banned. About 700,000 bins had to be taken out
of service or modified to meet stability requirements
• Extremely flammable contact adhesives
– In January 1978 contact adhesives which had a flash
point of -20 degrees F or lower were banned because
of extreme risk of accidental ignition of the vapors from
the solvent
MPD575 DF Health & Safety
Banned Products
• Lead-containing paint
– After February 1978 paint having 0.06 percent or
more of lead content in the dried film and
consumer products such as toys or furniture
finished with such paints were banned. The
hazard was lead poisoning resulting from very
young children eating bits of the lead-containing
paint
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Banned Products
• Asbestos-containing patching compounds
– Banned June 11,1978 because the loose asbestos
particles could be inhaled causing respiratory
disorders
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Banned Products
• Lawn Darts
– Banned December 1988. Lawn darts were 4 to 8
ounce metal shafts about 4 inches long and fitted
with 8 inch long plastic fins along with their rear
portions. They were generally used outdoors,
launched upward with an underhanded throw in an
attempt to land the dart on a target area located
several feet away. The dart could fall onto the
head or shoulders of a person, causing a severe
puncture-type injury. More than 600 injuries were
reported each year.
MPD575 DF Health & Safety
CPSC Standards
• Since the Regulatory Reform Act, the number of
banned products has drastically dropped
• The preferred method of regulation is CPSC
Standards, using inputs from industry, safety
organizations, technical societies, and government
agencies
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Injury and Death Statistics (1999)
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Trampoline
Nursery Products
Amusement Rides
All Terrain Vehicles
Fireworks
Toys
Go-Karts
Halogen Floor Lamps
Shopping Cart
6/13/2012
100,000
65,400
10,400
3,717
8,500
152,600
125,900
404 (fires)
21,600
Keith Warner
Trampoline
• Trampoline related injuries have almost tripled since
1991
• In 1999, CPSC estimates that almost 100,000 people
were treated in US hospital emergency rooms
• In 1991, by comparison, an estimated 37,500 people
were treated
• Since 1990, CPSC has received reports of 11 deaths
relating to trampoline use
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Trampoline
MPD575 DF Health & Safety
Trampoline
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Nursery Products
Nursery product related injuries and deaths
to children under age five by product
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Nursery Products
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Amusement Rides
• An estimated 10,400 hospital emergency room
treated injuries occurred in 1999
– 7,000 involving fixed rides
– 3,000 involving mobile rides
• An estimated 23.5 injuries per million attendance
occurred at fixed site parks in 1999
• The estimated annual average number of nonoccupational fatalities from 1987 through 1998 was
4.3 fatalities each year
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Amusement Rides
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All Terrain Vehicles
• From 1982 to 1999 there were a total of 3,717 deaths
from ATVs
• 1,310 victims (35% of the 3,716 total) were under 16
years of age
• 569 victims (15% of total) were under 12 years of age
• The percent of fatalities has increased from 7% or
less prior to 1985 to 9% percent for 1999
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All Terrain Vehicles
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Fireworks
• CPSC has reports of 16 deaths from fireworks in
1999
• Fireworks devices were involved in an estimated
8,500 injuries treated in US hospital emergency
rooms in 1999
• There was no increase in injuries in 1999 despite a
20% increase in the dollar value of fireworks imported
into the US
• About three times as many males were injured as
females
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Fireworks
MPD575 DF Health & Safety
Toys
• In 1999, there were an estimated 152,600 toy related
injuries treated in US hospital emergency rooms
• 78% of injuries for 1999 were to children under 15
years of age
• 46% were to children under 5
• Most of the victims (95%) were treated and released
from the hospital
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Toys
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Go-Karts
• An estimated 125,900 go-kart related injuries were
treated in US hospital emergency rooms from 19851996
• An average of 10,500 injuries per year
• About 81,000 injuries (65%) were to children under
15 years old
• The hospitalization rate for all ages was 5% and 3%
for under 15 years of age.
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Go-Karts
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Halogen Floor Lamps
• From January 1992 to March 30, 1998, CPSC has
received 260 reports of incidents involving halogen
torchiere-style floor lamps
• 232 were fire related
• Tubular halogen bulbs between 300 & 500 watts
– Represents temperatures from 970 degrees Fahrenheit to
1,200 degrees
– A 75 watt incandescent bulb operates at about 260 degrees
and a 150 watt bulb at 340 degrees
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Halogen Floor Lamps
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Shopping Carts
• An annual average of 21,600 children, 5 years
old and younger were treated in US hospital
emergency rooms from 1985-1996
• There has been a significant increase in the
number of these injuries between 1985 and
1996
• An annual average of 12,800 of these children
were treated for falls from the carts
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Shopping Carts
MPD575 DF Health & Safety
Faulty Consumer Product Designs
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Women’s shoes
Sports equipment
Ladders
Power tools and equipment
Toys
Stairs and stairways
Mechanical power presses
Food preparation equipment
MPD575 DF Health & Safety
Women’s Shoes
• Failure: women who fall, trip, or lose their balance
when their heel suddenly separates from the sole of
the shoe
• Heels are typically attached to the soles with special
barbed nails which have been heat treated
• Common method uses five nails
• While style & aesthetics play a major part in the
design, the typical heel attachment method is not
adequate
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Sports Equipment
• One example is of a practice weight
slipped over the handle of a softball
bat that flew off and struck someone in
the face
• The weight was a slug of cast iron in
the shape of a doughnut
• The manufacturer designed one for
softball bats and one for baseball bats
• The user made a mistake and used
the wrong one
• A foreseeable misuse of the product
was missed by the designer
• A small change in the diameter could
have designed the hazard out of the
product
MPD575 DF Health & Safety
Ladders
• One of the leading causes of household
injuries is falls from portable ladders
• About 90,000 ladder-related injuries take place
each year
• An ANSI committee, the A14 committee,
worked to develop an acceptable standard
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Ladders
• Three different classes of portable
ladders were established, depending on
their load-carrying capabilities and their
intended use
– Class III: light duty, for use around
the home
– Class II: medium duty
– Class I: heavy-duty industrial
ladders
Class II
Class I
• Minimum dimensions were established
for certain components and
performance tests were prepared to
ensure structural integrity
Class III
MPD575 DF Health & Safety
Ladders
• Clear, definite, and unambiguous instructions
for the proper use, care and storage of
portable ladders were prepared
• Comprehensive warning labels were
developed
• Specifications for where the labels needed to
be placed and how durable they needed to be
MPD575 DF Health & Safety
Power Tools & Equipment
• Principal hazard in these tools is accidental
contact with the working element of the tool
• Although portable circular saws had a guard
over the upper half of the blade, the lower half
was commonly left exposed
• If the saw was set aside with the blade still
moving, the saw could “walk” rapidly and strike
the user
MPD575 DF Health & Safety
Power Tools & Equipment
• A guard was finally developed
which used a spring-loaded
visor to cover the lower part of
the blade
• As soon as the saw blade
came out of the cut, the spring
returned the guard to the
closed position
• This solution has been widely
adopted for portable circular
saws
MPD575 DF Health & Safety
Toys
• Toys that have resulted in injuries from
predictable hazards that should have been
revealed by a routine test program
– Double barreled pop gun
– Water gun
MPD575 DF Health & Safety
Double Barreled Pop Gun
• Pump and lever action
compressed a charge of air,
contained with a cork
• When the trigger was pulled,
the air discharged with a loud
bang
• The expelled cork was caught
by a fitting glued to the end of
the barrel so that the pump
action could recycle it for the
next shot
MPD575 DF Health & Safety
The Failure
• A 4 year old was playing the toy. He cocked
the gun, and fired. He accidentally hit his
brother between the eyes with the corks and
the retaining fitting
• The glue joint between the fitting and the gun
barrel had failed
MPD575 DF Health & Safety
Water Gun
• This water gun could hold about a quart of
water
• Rubber tubing was closed off at its lower
end by a metal clip, and was fitted with a
filling valve at the top
• It was loaded under pressure by attaching
the valve to the end of a garden hose
• The valve closed when the gun was full
MPD575 DF Health & Safety
The Failure
• If the user tried to fill the gun beyond its
capacity, they could get hit by the clip that held
the bottom end closed
• Overfilling was a predictable thing for young
kids to attempt and was overlooked by the
designer
MPD575 DF Health & Safety
Stairs and Stairways
• Can be very hazardous
• Most of the hazards are easily identifiable and
can be reduced or eliminated by proper
attention to design detail
• Design detail requirements for interior and
exterior stairs are included in local, state and
national building codes
MPD575 DF Health & Safety
Stairs and Stairways
• Hazards:
– Lack of uniformity in the height of the risers and
the depth of the stair treads
– Lack of suitable handrails
– Inadequate overhead clearance
• Requirements for each of these hazards exist
MPD575 DF Health & Safety
Mechanical Power Presses
• One example is of a small vertical-stroke machine
used to punch holes in paper
• The operator presses the foot pedal and the paper
was cut in less than half a second
• Although there was a guard, the operator could reach
around to remove an obstruction and still press the
foot control
• The operator lost two fingertips
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Food Preparation Equipment
• Example: Food processors
• A switch cuts off the power when the lid is opened
• There was an opening in a particular design that was
large enough that the user could fit their hand into the user lost three finger tips
• Later versions of the machine incorporated the
obvious design improvement of automatic shutoff
MPD575 DF Health & Safety
Food Preparation Equipment
• Other examples
– Meat cutting saws: Even with a
push piece and warnings, there
still is not an effective blade guard
to protect the user’s hands
– Dough brakes that are small
rolling mills bakers use to roll out
chunks of dough: If the bakers
push the dough too far forward,
the fingers or hands can be
injured. The table was extended
to prevent the user from being
able to reach into the ‘nip’ point.
A pressure bar in front of the
operator will shut off the machine
is they get too close to the table.
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Recalls
• Protects the public from the unreasonable risk
of injury or death
• Consumers can report unsafe products
– Online at…
• General complaints ( http://www.recalls.gov/ )
• Food & drug complaints ( http://www.fda.gov/ )
• Business complaints ( http://www.ftc.gov/ )
– General list of agencies
• http://www.cpsc.gov/federal.html
MPD575 DF Health & Safety
High Chair Recall
11/27/00 WASHINGTON,
D.C. - In cooperation
with the U.S. Consumer
Product Safety
Commission (CPSC),
Cosco Inc., of
Columbus, Ind., is
voluntarily recalling
about one million
Options 5 High Chairs
MPD575 DF Health & Safety
The Failures
• In the recline position, the seats can separate
from the frame and fall to the ground
• In the upright position, the seats can slip from
their set height position to the lowest position
or can fall to the ground
• Additionally, some seats were sold with a
metal restraint anchor that can slip through the
back of the seat allowing the child to fall to the
ground
MPD575 DF Health & Safety
The Injuries
• Infants and toddlers can suffer head, face and bodily
injuries
• Cosco and CPSC have received 168 reports of
incidents involving the high chairs' seats or restraints,
including 57 injury reports, primarily to the head and
face
• Two children reportedly suffered slight concussions;
twelve children were monitored for head injuries; and
others suffered swollen eyes, bloody noses and lips,
bumps and bruises
MPD575 DF Health & Safety
The Resolution
• Cosco is offering consumers two types of repair kits,
depending on the date their high chair was
manufactured
• To prevent seat separation, all kits will contain a
redesigned handle that stays out and fits over the
frame each time the seat is used in the recline
position
• In many incidents in the recline position, the handle
was not over the frame of the high chair
MPD575 DF Health & Safety
L.L. Bean Inc. Announce Recall of
Toddlers' Slippers
• The draw-cord around the ankle of these slippers can
break and release the toggle used to tighten the
draw-cord
• The toggle is a choking hazard to young children
• L.L. Bean has received one report of a 12
month-old child
pulling the toggle
off of his slipper
• No injuries
were reported
MPD575 DF Health & Safety
Kellogg Announce Recall of Toy Cars
Inside Boxes of Cereal
• The tires can detach from the wheels of these
cars, posing a choking hazard for young
children
• Kellogg has received two
reports of the tires
detaching from the wheels
of these toy cars
• No injuries have
been reported
MPD575 DF Health & Safety
Design for Health & Safety
•
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Introduction
Manufacturing Hazards
Consumer Products
Automotive Products
Driver Distraction
Key Principles
Case Studies
References
MPD575 DF Health & Safety
Automotive
• National Highway Traffic Safety Administration
– NHTSA is responsible for reducing deaths, injuries and
economic losses resulting from motor vehicle crashes
– NHTSA investigates safety defects in motor vehicles,
sets and enforces fuel economy standards, helps
states and local communities reduce the threat of
drunk drivers, promotes the use of safety belts, child
safety seats and airbags, investigates odometer fraud,
establishes and enforces vehicle anti-theft regulations
and provides consumer information on motor vehicle
safety topics.
MPD575 DF Health & Safety
Federal Motor Vehicle Safety Standards
(FMVSS) and Regulations
• Manufacturers of motor vehicle and equipment
items must confirm and certify compliance
• FMVSS 209 was the first standard to become
effective on March 1, 1967
• New standards and amendments to existing
standards are published in the Federal
Register
MPD575 DF Health & Safety
FMVSS
• These Federal safety standards are regulations
written in terms of minimum safety performance
requirements for motor vehicles or items of motor
vehicle equipment. These requirements are
specified in such a manner "that the public is
protected against unreasonable risk of crashes
occurring as a result of the design, construction,
or performance of motor vehicles and is also
protected against unreasonable risk of death or
injury in the event crashes do occur."
MPD575 DF Health & Safety
FMVSS
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Crash Avoidance (FMVSS 100 Series)
Crashworthiness (FMVSS 200 Series)
Post-crash Standards (FMVSS 300 Series)
Other Regulations (FMVSS 500 Series)
Labeling and Consumer Information
Requirements
MPD575 DF Health & Safety
Sample Form
MPD575 DF Health & Safety
Sample Form
MPD575 DF Health & Safety
Sample Form
MPD575 DF Health & Safety
Automotive Airbags
• These hazards will be increasing in the future due to the
increase in the number of airbags and pedestrian protection
countermeasures now required by EEC.
• The recommended method to disable the airbag is to
disconnect the battery cable and wait 10-30 mins for the
system to deactivate. Obviously, this is not feasible in most
accident situations.
• Even getting to the battery will be difficult now with the various
pyrotechnic devices that will be in the hood area for pedestrian
protection (Volvo has one in production now).
• A master airbag control unit switch should be provided so the
airbags can be manually deactivated.
MPD575 DF Health & Safety
Federal Lighting Equipment Locations
Requirements
MPD575 DF Health & Safety
Safety Recalls
• NHTSA is responsible for the administration of
national safety recalls by manufacturers or
distributors of motor vehicles and items of motor
vehicle equipment where a safety defect or
noncompliance with a FMVSS rule has been
determined
• The agency also conducts investigations of alleged
safety defects and tests for compliance with FMVSS
MPD575 DF Health & Safety
Automotive Airbags
• As automakers strive to make vehicles safer for motorists in the
event of an accident, the vehicles have been getting more
dangerous for first responders.
• The addition of multiple airbags in the cars have caused a
significant safety hazard to first responders from:
– Injury from the pyrotechnic explosion that results from shorting
the airbag control unit when the jaws of life are used to cut a
victim out of the car or from a vehicle fire.
– Loss of hearing from the explosion
• There needs to be an established area where the airbag control unit
and pyrotechnic charge resides so the first responders can avoid
cutting them in extractions.
• This information then should be identified visually on the vehicle
and provided to the various departments through documentation.
MPD575 DF Health & Safety
Light Weight Materials
• The auto manufactures are also busy trying to meet the new CAFE
regulations for fuel economy.
• This has placed a heavy emphasis on making vehicles lighter
through the use of aluminum, high strength steel and magnesium .
• High strength steel has increased the cutting requirement on the
jaws of life
• Magnesium is especially dangerous when it is on fire because
spraying it with water when it is on fire results in the formation of
explosive hydrogen gas.
• Many fire departments have no idea where these metals are located
and how much of it exists.
• There needs to be documentation provided to the first responders
so they can effectively extract the victims and fight these fires.
MPD575 DF Health & Safety
Design for Health and Safety
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Introduction
Manufacturing Hazards
Consumer Products
Automotive Products
Driver Distraction
Key Principles
Case Studies
References
MPD575 DF Health & Safety
Driver Distraction Background
•Driver distraction is a serious issue in automotive safety
•Personal electronic devices and advanced vehicle electronics
are bombarding drivers with increasing levels of information
•Paradoxically, consumers are demanding more high tech
features inside their vehicles
•It is important to keep driver safety in mind when designing
vehicle infotainment systems
Driver Distraction
•NHTSA defines distracted driving as the following
•Specific type of inattention that occurs when drivers divert attention from the
driving task to some other activity
•Examples of distractions to the driving task are:
•Entering destinations in navigation systems
•Placing/answering phone calls
•Sending text messages
•Reach for items inside the vehicle
•Talking with other passengers
•When designing vehicle systems, the goal should be to
minimize or eliminate these driving distraction risks
Driver Distraction
•NHTSA reports in 2008 that 5,870
people died and 500k were injured in
driver distraction related crashes
•In a National Motor Vehicle Crash
Causation Survey, 11% of accidents
studied involved driver distraction
•The table to the right shows the
increased risk of being involved in a
crash by certain secondary tasks
•i.e.
reaching for a moving object increases
your risk for crashing 8 times
•
It is important to ask yourself
regarding your product’s design “Does my product reduce or increase
the risk of any of these types of
distractions?
Types of Driver Distractions
•There are three classifications of driver distractions
•Visual Distractions
•Require the driver to look away from the roadway to visually obtain information
•Manual Distractions
•Tasks that require the driver to take a hand off the steering wheel to manipulate a
device
•Cognitive Distractions
•Mental workload associated with a task that involves thinking about something other
than the driving task
•The goal of the automotive designer should be to reduce the risk
of these distractions by implementing the following guidelines
provided by the Alliance of Automotive Manufacturers
Ways to Reduce Driver Distraction
•Visual
Distractions
•Place in-vehicle displays and high-use
controls as high as possible in the interior
without obstructing field of view
•Make sure displays and controls are well
laid out and free of clutter
•Design displays so they are free from
sunlight glare or reflections
•Disable video and moving images while the
vehicle is in motion
Ways to Reduce Driver Distraction
Manual Distractions
When using the system, the driver
must be able to leave one hand on
the wheel
Implement hands-free speechbased communication systems
Avoid system inputs that are timecritical – let the driver control the
pace
Ways to Reduce Driver Distraction
Cognitive Distractions
•In-vehicle systems should use
appropriate symbols and text
•The task should be simple
enough to complete with brief,
sequential glances
Design for Health and Safety
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Introduction
Manufacturing Hazards
Consumer Products
Automotive Products
Driver Distraction
Key Principles
Case Studies
References
MPD575 DF Health & Safety
Key Principles
• Industrial and commercial products
• Labels
• Safety Standard (SS) examples
– Walk behind lawnmowers
– Cigarette lighters
– Residential garage door operators
– Bicycle helmets
– Swimming pool slides
– Clothing
– Full size baby cribs
– Matchbooks
– Architectural glazing materials
– Toys
MPD575 DF Health & Safety
Industrial & Commercial Products
Effective October 31,1989, all machinery and
equipment are required by OSHA to provide
single point lockouts
– Lockouts secure the equipment in such a manner
that it cannot be started by someone other than the
person servicing the equipment
MPD575 DF Health & Safety
Industrial & Commercial Products
Zero Energy State
– Requires that the equipment designer recognize
that start-up operations can result in energy
storage, which can cause injury to the operator
“But officer, I didn’t know the gun was loaded”
– Designer must protect the user of the equipment
from the consequences of the release of
unexpected energy
– Springs and stored capacitive charges are
common sources of energy
MPD575 DF Health & Safety
Industrial & Commercial Products
Guards and lock-outs need to be designed such
that it is impossible for the operator to get any
part of their body into the danger zone and still
operate the machinery
MPD575 DF Health & Safety
Criteria Designers Can Use For Assessing
the Requirement for a Warning Label
• List the intended and foreseeable uses of the product
• Determine the nature of the hazards connected with
each use
• Assess the possibility of injury to persons or of
damage to property because of an accident involving
the hazard
• Estimate the probability that such an accident will
take place
• The severity of the resulting injury or damage
MPD575 DF Health & Safety
Human Factors with Respect to
Warnings
• Human factors research has shown that an
effective warning must:
– Attract the person’s attention immediately
– Be strong enough to be clear and convincing
– Show how to avoid exposure
• The warning must be placed where it can be
easily seen in connection with the related
hazard & must contain graphic symbols which
alert the user
MPD575 DF Health & Safety
Warnings
• Warnings found in owners manuals are not
very effective
• Verbal warnings can be quickly forgotten
• No substitute for a written warning located
near the hazard
MPD575 DF Health & Safety
Key Graphic Symbols
• Danger: most forceful and exciting; to be used when
it is 100% certain that exposure to the hazard will
result in severe or fatal injury to the user
• Warning: Probability of severe injury or damage is
less than 100%, but the possibility of severe injury is
present
• Caution: Probability of injury is less than 100%, the
possibility for severe or fatal injury is absent, but
minor injury is probable
MPD575 DF Health & Safety
Colors
• Most effective to least
– Red, orange, yellow, black
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Should not use blue, green or purple
Consider the background color
Black on white or yellow is highly visible
Red on white is only fair
Red on yellow or red on green are very difficult
to see
MPD575 DF Health & Safety
Shapes of Labels
• Rounded or softly curved boundaries have less
attention-getting value
• Use shapes with square corners
• Rectangles are the best choice
• Triangles and squares are the next best
choices
• Warning labels with five or more sides are
seldom used on industrial equipment or
consumer products
MPD575 DF Health & Safety
Examples
• Power lawn mowers may use the warning:
– Do NOT place hands or feet under deck.
• This warning does not let the user know the
nature of the consequences of not following
the instructions
• Suggested modification:
– Do NOT place hands or feet under deck.
– Your fingers or toes could be cut off.
MPD575 DF Health & Safety
Automotive Example
Warning on visor:
Warning on inside of visor:
MPD575 DF Health & Safety
Convertible Top Warning Label
Label located near release latch for top (yellow
on black):
MPD575 DF Health & Safety
Other Label Examples
MPD575 DF Health & Safety
Safety Standard for Walk Behind Power
Lawn Mowers
• Effective on December 31, 1981
• Prescribes safety requirements
– Labeling
– Performance
• Intended to reduce the risk of injury to consumers
caused by contact, primarily the hand and foot, with
the rotating blade of the mower
– Prevent the blade from operating unless the operator
actuates the control
– Require continuous contact with the control
– Cause the blade in motion to come to a complete stop
within 3.0 seconds after release of the control
MPD575 DF Health & Safety
Safety Standard for Cigarette Lighters
• Effective after July 12, 1994
• Disposable and novelty lighters
• Resistant to successful operation by children
younger than 5 years old
• Applies to both manufactured and imported
MPD575 DF Health & Safety
Safety Standard for Residential Garage
Door Operators
• Effective after January 1993
• Intended to reduce the risk of fire, electric
shock, or injury to persons, including
entrapment protection
MPD575 DF Health & Safety
Safety Standard for Bicycle Helmets
• Effective after March 1995, updated March
1999
• All bicycle helmets must be capable of meeting
the following requirements/tests:
– Peripheral vision
– Positional stability
– Dynamic strength of retention system
– Impact-attenuation
• Updates still required: Helmets should be replaced
every 5 years due to degradation of protective foam
MPD575 DF Health & Safety
•
Safety Standard for Swimming Pool
Slides
Reduce or eliminate the unreasonable risks of death or
injury associated with swimming pool slides effective after
July 1976
• Recommendations regarding the installation,
maintenance, and intended use of swimming pool slides
• Risks include:
– Quadriplegia and paraplegia resulting from users
sliding down the slide in a head first position and
striking the bottom of the pool
– Leg fractures resulting from feet first entry
– Impact of sliders with other people in the pool
– Falls from the slide ladder
MPD575 DF Health & Safety
Safety Standard for Clothing
• Guidelines for drawstrings on children's
outerwear
• Flammability requirements
– Class 1: Normal flammability
• Time of flame spread is more than 7 seconds
– Class 2: Intermediate flammability
• Time of flame spread is from 4 to 7 seconds
– Class 3: Rapid and intense burning
• Time of flame spread is less than 4 seconds
MPD575 DF Health & Safety
Safety Standard for Full Size Baby
Cribs
• Requirements for interior dimensions
• Rail height
• Spacing of crib components
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Slats
Spindles
Crib rods
Corner posts
• All wood surfaces shall be smooth and free from
splinters
• No horizontal bar, ledge, projection, or other surface
accessible to a child inside the crib capable of being
used as a toehold
MPD575 DF Health & Safety
Safety Standard for Matchbooks
• Risks of burn injuries, eye injuries caused by
burning fragments, and fires started by
extinguished batches which had left a lengthy
afterglow period
• Requirements cover:
– Friction location
– Cover shall remain closed (Instruction to user)
– Matchhead condition
– Matchhead location
• Effective after May 1978
MPD575 DF Health & Safety
Safety Standard for Architectural
Glazing Materials
Materials include storm doors, bathtub and
shower doors and enclosures, and sliding-type
doors used on patios
– The objective was to reduce the hazards of injury
from glass being broken as a result of human
contact
– Nearly 200,000 lacerations, contusions, abrasions
or other injuries were associated with architectural
glass products each year before the standard in
1977
MPD575 DF Health & Safety
Safety Standard for Toys:
For Use By Children of Any Age
• No shock or thermal hazards in any electrical
toys
• No toxic materials
For Use By Children Up To Age 8
• Severely limited lead in toy paints
• No heating elements in electronically operated
toys
• No sharp points or sharp edges
MPD575 DF Health & Safety
Safety Standard for Toys:
For Use By Children Up To Age 3
• Must withstand use and abuse, must be break
resistant
• No small parts or pieces which could become
lodged in the throat
• Infant rattles must be large enough to not
become lodged in the throat and cannot
separate into small pieces
MPD575 DF Health & Safety
Voluntary Safety Standards
• Adopted by the toy industry
• Includes:
– Age and safety labels on toys
– Making squeeze toys and teething rings so large
that they cannot get stuck in an infant’s throat
– Limiting the length of strings on crib and playpen
toys to 12 inches to prevent possible strangulation
MPD575 DF Health & Safety
More Standards
• Chests for storing toys are required to have
lids which stay open at any level to prevent the
lid from dropping unexpectedly and striking the
child or trapping them inside the box.
MPD575 DF Health & Safety
Design for Health and Safety
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Introduction
Manufacturing hazards
Consumer products
Automotive products
Driver Distraction
Key Principles
Case Studies
References
MPD575 DF Health & Safety
Case Studies
• Cases submitted as part of a proposal to the
National Safety Council that it create an
Institute for Safety Through Design
• Computer Manufacturer
• Aircraft Manufacturer
• Copier Manufacturer
• Construction and Farming Equipment
Manufacturer
MPD575 DF Health & Safety
Computer Manufacturer
• An electronic panel drilling machine was
difficult to operate
• Workers had to bend and reach to perform
tasks, and operator comfort, product quality
and performance suffered
• A study was performed and new machines
designed for better body mechanics were
acquired
MPD575 DF Health & Safety
Computer Manufacturer Results
• In the first year, labor costs were reduced by
$270,000
• Yield increased $420,000
• Productivity improved
• Injuries were reduced
MPD575 DF Health & Safety
Aircraft Manufacturer
• An assembly operation required standing on a
platform to get visual and physical access to
parts being assembled
• Shoulder strain injuries resulted from installing
operations, done above shoulder level
• Work methods were redesigned
MPD575 DF Health & Safety
Aircraft Manufacturer Improvements
• An assembly stand mounted on a hydraulic
height adjustable cart permitted drilling,
riveting and installing parts in a hands-free
manner and was performed below shoulder
height, with good visual and physical access
MPD575 DF Health & Safety
Aircraft Manufacturer Results
• No more strain injuries occurred
• Production increased from 2 to 4 units a week
• Estimated annual cost savings was $52,800
MPD575 DF Health & Safety
Copier Manufacturer
• A copier machine with highly repetitive
assembly tasks was estimated to have
workers’ compensation costs 2.5 times higher
than the corporate average
• A redesign study showed how hazards could
be reduced and how to simplify the design
– reduction in the number of parts
– use of standard parts
MPD575 DF Health & Safety
Copier Manufacturer Results
• Substantial reduction in production costs
• Reduced hazards
MPD575 DF Health & Safety
Construction & Farming Equipment
Manufacturer
• Backhoe assembly line
• The work done inside the operator’s cab forced
the worker into stressful and awkward
positions and required repetitive hand tool use
• The workers doing this task experienced back
injuries and only young employees would
accept this assignment
MPD575 DF Health & Safety
Construction & Farming Equipment
Manufacturer
• A team worked to redesign the operations
• The work could now be done prior to
installation of components in the cab, allowing
the assembler to work in a good upright
position
• Results:
– Major reduction in production time & hazards
MPD575 DF Health & Safety
Design for Health and Safety
•
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Introduction
Manufacturing hazards
Consumer products
Automotive products
Driver Distraction
Key Principles
Case Studies
References
MPD575 DF Health & Safety
References
• Engineering Design for Safety, Thomas A. Hunter
1992
• Safety Through Design, Wayne C. Christensen and
Fred A. Manuele
• www.safetyonline.com
• www.cpsc.gov
• www.ftc.gov/ftc/consumer.htm
• www.osha.gov
• www.nationalsafetycouncil.org
• www.consumer.gov
• www.detnow.com/community/recalls
MPD575 DF Health & Safety
References
Alliance of Automotive Manufacturers (AAM) Guidelines for
Driver Distraction
http://iems.net/2005/webzine/newsletter/v10n2/Overseas_report/
AAM_Guidelines.pdf
•
NHTSA Distracted Driving Research Plan
http://www.nhtsa.gov/Research/Human+Factors/Distraction